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Fronius CMT Twin User Information

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/ Perfect Charging /
Perfect Welding
CMT Twin
Process description and
commissioning
42,0426,0138,EN 003-28082017
/ Solar Energy
User information
System extension

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  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy User information CMT Twin Process description and System extension commissioning 42,0426,0138,EN 003-28082017...
  • Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.

  • Page 5: Table Of Contents

    System concept ............................ Functional principle ..........................Configurations............................Dimensioning of the robot ........................Measures to increase system availability....................Note for TimeTwin welding using a CMT Twin system ................. System components required ........................System components required ....................... Application example........................... Application example..........................Installation and commissioning Safety.................................
  • Page 6 Material transfer ............................ Applying the 'HD' ('Heavy Duty') configuration................... Available characteristics ........................Description of characteristics ........................ Configuring the system ......................... Stick out ..............................Use 'Speed' configuration .......................... Available characteristics ........................Description of characteristics ........................ Configuring the system ......................... Stick out ..............................Use 'Root' configuration ..........................

  • Page 7: General

    General...

  • Page 9: General

    General System concept CMT Twin is a high performance welding process that combines the advantages of CMT welding and Twin welding. In addition to numerous other benefits, it offers a very high weld- ing speed and simple control of the process.

  • Page 10: Dimensioning Of The Robot

    Robacta TC 1000 Twin Electromagnetic welding torch cleaner for ferromagnetic base materials Note for NOTE! When welding the TimeTwin process using a CMT Twin system, the TimeTwin weld- "TimeTwin Digital" software needs to be enabled on both power sources. ing using a CMT...

  • Page 11: System Components Required

    System components required System compo- 2 TPS 5000 CMT nents required with DSP software version 5.01.063 or higher 2 RCU 5000i with database version 908 or hig- Use 2 FK 4000 R or 1 FK 9000 for: FK 4000 R hosepack lengths of up to 4.25 m (14.76ft.) 100 % duty cycle (10min/40°C) at 360...
  • Page 12 2 VR 7000 CMT or 2 VR 1550 VR 7000 CMT VR 1550 2 Robacta Drive CMT drive units with wire buffer and hosepacks 1 LHSB-HUB...
  • Page 13 1 Robacta Twin Compact Pro torch neck and mounting bracket 2 inner liners 1 wrench for nozzle fitting and con- tact tip 2 nozzle fittings 2 spatter guards 2 contact tips 1 gas nozzle 2 TCP tips 1 wrench for union nut on drive units Robot interface for connecting power source to the robot control...

  • Page 14: Application Example

    Application example Application ex- ample (2) (3) (10) (21) (16) (14) (13) (19) (12) (22) (20) (18) (15) (11) (17) Connection to robot control (12) Robot Robot interface (13) Drum coil Connection to robot interface (14) Drum coil Interconnecting hosepack (15) FK 9000 R or FK 4000 R cooling unit...

  • Page 15: Installation And Commissioning

    Installation and commissioning...

  • Page 17: Safety

    Safety Safety Observe the following safety instructions for all work described in these operating instruc- tions. WARNING! Work that is carried out incorrectly can cause serious injury or dam- age. All the work described below must only be carried out by trained and quali- fied personnel.

  • Page 18: Notes Regarding The Installation Of Fronius System Components

    Notes regarding the installation of Fronius system components Installation and NOTE! Install and commission Fronius system components (power source, wire- commissioning of feed unit, cooling unit, hosepack, RCU 5000i, LHSB-HUB, etc.) according to the Fronius system operating instructions of the relevant device.

  • Page 19: Fitting Wearing Parts To The Torch Neck

    Fitting wearing parts to the torch neck Fitting wearing parts to the torch neck...

  • Page 20: Fitting The Mounting Bracket And Torch Neck

    Fitting the mounting bracket and torch neck Fitting the mount- ing bracket to the robot Screw the torch neck and drive 3x M6x12 units to the mounting bracket M6x12...
  • Page 21 Only screw in loosely to begin with - do not tighten. Only tighten the screws once all components have been properly aligned with each other - step 6. This will avoid placing the drive units under excessive strain.

  • Page 22: Earth Connection

    Earth connection Earth connection NOTE! Each power source must have its own dedicated earthing cable routed as shown. Separate earthing cable Shared earthing cable, earthing socket Separate earthing cable laid in a loop Earthing cable coiled...

  • Page 23: Recommendation To Minimise Arc Blow

    Recommenda- NOTE! To minimise arc blow, tion to minimise weld away from the earthing con- arc blow nections.

  • Page 24: Connecting The Lhsb-Hub With The Power Sources And Wire-Feed Units

    Connecting the LHSB-HUB with the power sources and wire-feed units Connecting the Connect the lead power source to connection (1) on the LHSB-HUB LHSB-HUB with Connect the wire-feed unit of the lead power source to connection (2) on the LHSB- the power sourc- es and wire-feed Connect the trail power source to connection (3) on the LHSB-HUB...

  • Page 25: Connecting To The Robot Control

    Refer to the operating instructions for the respective interface for instructions on con- necting the welding system to the robot control. Robot interfaces There are two special robot interfaces for CMT Twin available for connecting to the robot for CMT Twin control:...

  • Page 26: Twin Fieldbus Systems

    Application example: Part/device Part/device Standard interface Power source Standard interface Power source LocalNet connection Connection to robot control LocalNet connection Robot control Twin fieldbus The following Twin fieldbus systems can be used to connect to the robot control for Twin systems processes: Twin DeviceNet fieldbus robot interface...

  • Page 27: Standard Fieldbus Systems

    (2) (3) Standard fieldbus The following standard fieldbus systems can be used to connect to the robot control for systems Twin processes: DeviceNet fieldbus robot interface CanOpen fieldbus robot interface Interbus CU fieldbus robot interface Interbus LWL fieldbus robot interface Profibus 1.5 MB fieldbus robot interface Signals must be connected logically by the robot control when standard fieldbus systems are used.

  • Page 28: Description Of Signal Statuses

    Description of NOTE! During twin-wire welding (CMT Twin), the signal statuses have no influ- signal statuses ence on which power source operates as the lead or trail power source. This is decided by the characteristic selection on the RCU 5000i.

  • Page 29: Check Compatibility Of Power Sources And Remote Controls

    Check that the power source DSP soft- ware version is 5.01.063 or higher If not, the power source cannot be used for CMT Twin applications Checking the NOTE! Check the database version of both RCU 5000i devices. RCU 5000i data-...
  • Page 30 Open "Machine pre-sets" on the RCU 5000i menu Select the "Version" screen Check that the RCU 5000i database version is DB 0908 or higher If not, update the RCU 5000i firmware...

  • Page 31: Checking The Characteristics Version

    Checking the NOTE! The welding start-up configured for CMT Twin is only available with char- characteristics acteristics version V2.9.4. Check the characteristics version to ensure that the...
  • Page 32 In the relevant "Data" screen, press F4 "Filler metal" The 1st screen in the wizard appe- ars ("Select a filler metal") Apply the desired CMT Twin settings depending on the application The "Welding program" screen is dis- played again once the relevant settings...

  • Page 33: L/R Alignment - Aligning Welding Circuit Inductivity And Welding Circuit Resistance

    L/R alignment - aligning welding circuit inductivity and welding circuit resistance Safety WARNING! If the equipment is used or tasks are carried out incorrectly, serious injury or damage may result. All the work described below must only be carried out by trained and qualified personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe-...
  • Page 34 The 1st screen in the wizard appears ("Actual values") Press F2 "Forward" "Actual values" screen The 2nd screen in the wizard appears ("Preparations") Follow the instructions given in the "Preparations" screen NOTE! The contact between the earthing clamp and workpiece must take place on a cleaned workpiece surface.
  • Page 35 Once the L/R alignment is complete, the values obtained for welding circuit resistance (R) and inductivity (L) appe- ar in the 4th screen of the wizard ("Confirmation"). Press F2 "Done" "Confirmation" screen The last "Data" screen called up appe- ars. Machine pre-sets: e.g.

  • Page 36: Welding Start-Up

    Once the trail wire electrode receives the start signal, it then also starts the welding process NOTE! The welding start-up configured for CMT Twin is only available with char- acteristics version V2.9.4. Refer to the "Checking the characteristics version" sec- tion for instructions on how to check the characteristics version.

  • Page 37: Start Delay Parameter Correction

    NOTE! If both wire electrodes are to weld with the CMT process, then the follow- ing must be selected for each wire electrode in the "Filler metal/Select a shielding gas" menu on the RCU 5000i: which wire electrode is the lead elec- trode (wire electrode 1) which wire electrode is the trail electro- de (wire electrode 2)

  • Page 38: Pulse/Cmt Welding

    Pulse/CMT welding Process descrip- Properties of lead wire electrode (pulse): tion pulse/CMT deep fusion penetration welding high deposition rate Properties of trail wire electrode (CMT): extremely good filling of the weld seam improved process stability Symbol Explanation Trail wire electrode (CMT) Lead wire electrode (pulse) Weld pool Pulsed arc with droplet transfer...

  • Page 39: Cmt/Cmt Welding

    CMT/CMT welding Process descrip- NOTE! Different characteristics are used for each wire electrode in this process tion CMT/CMT variant. welding Properties of lead wire electrode (CMT): shorter arc than the trail wire electrode higher arc power than the trail wire electrode starts the welding process Properties of trail wire electrode (CMT): arc tuned to the weld pool...

  • Page 40: Single-Wire Welding

    Single-wire welding Special features A signal is emitted from the robot control that triggers welding from one power source only and advantages (single-wire welding). Depending on the position of the torch neck or the out-of-position weld seam, single-wire welding can be performed from either the lead or trail power source.
  • Page 41 I (A) I (A) t (s) t (s) Pulse (single-wire, trail power source): Welding cur- Standard (single-wire, trail power source): Welding rent/time curve and schematic representation of the current/time curve and schematic representation of material transfer the material transfer Symbol Trail wire electrode Lead wire electrode Weld pool...

  • Page 42: Applying The 'Hd' ('Heavy Duty') Configuration

    Applying the 'HD' ('Heavy Duty') configuration Available charac- Characteristic Welding pro- Material Wire di- Shielding gas teristics number cess ameter 1474 Pulse G3Si1 M21 Ar+18% CO 1476 G3Si1 M21 Ar+18% CO 1477 G3Si1 C1 100% CO Lead 1478 G3Si1 C1 100% CO Trail Description of characteristics...
  • Page 43 CAUTION! The power sources must be switched on for the following work. This poses a risk of injury and material damage due to: welding current unintentional ignition of an arc emerging wire electrodes Until all work is completed, ensure that: welding is not initiated by any power source the wire electrodes are not fed out NOTE! The work described below is performed on both power sources using the...

  • Page 44: Stick Out

    In the relevant "Data" screen, press F4 "Filler metal" The 1st screen in the wizard appe- ars ("Select a filler metal") Depending on the application, apply the settings for both power sources on both RCU 5000i devices NOTE! If both wire electrodes are to weld using the CMT process, then the fol- lowing must be selected for each wire electrode (each power source) on the RCU 5000i: which wire electrode is the lead electrode...

  • Page 45: Use 'Speed' Configuration

    Use 'Speed' configuration Available charac- Characteristic Welding pro- Material Wire di- Shielding gas teristics number cess ameter 1470 Pulse G3Si1 M21 Ar+18% CO 1471 G3Si1 M21 Ar+18% CO 1472 Pulse G3Si1 M21 Ar+18% CO 1473 G3Si1 M21 Ar+18% CO 1479 G3Si1 M21 Ar+18% CO 1500...

  • Page 46: Configuring The System

    1510 Puls Lap joint, fillet weld High frequency pulsed arc; arc light-gauge sheet length kept short; optimised for 1510 high welding speeds and alumini- Lead with 1511 1511 CMT Lap joint, fillet weld CMT arc; higher current in the Trail light-gauge sheet arc-on phase;...
  • Page 47 Use the adjusting dial to select "MIG/ MAG synergic welding" from the RCU 5000i menu Press the OK button The last "Data" screen called up appe- In the relevant "Data" screen, press F4 "Filler metal" The 1st screen in the wizard appe- ars ("Select a filler metal") Depending on the application, apply the settings for both power sources on...

  • Page 48: Stick Out

    Stick out Lead Trail 10 mm (0.39 in.) Stick out and distance of the wire electrodes...

  • Page 49: Use 'Root' Configuration

    Use 'Root' configuration Available charac- Characteris- Welding pro- Material Wire di- Shielding gas teristics tic number cess ameter 1524 Pulse G3Si1 M21 Ar+18% CO 1525 G3Si1 M21 Ar+18% CO Lead 1526 G3Si1 M21 Ar+18% CO Trail Description of characteristics 1524 Puls Root pass Pulsed arc;...
  • Page 50 NOTE! The work described below is performed on both power sources using the RCU 5000i. Use the adjusting dial to select "MIG/ MAG synergic welding" from the RCU 5000i menu Press the OK button The last "Data" screen called up appe- In the relevant "Data"...

  • Page 51: Standard Welding Parameter Values For Fillet Welds

    Standard welding parameter values for fillet welds Standard welding NOTE! The following specifications are standard values determined under labo- parameter values ratory conditions. for fillet welds Filler metal and welding position: Shielding gas: M21 Ar+18% CO , 2 x 12 l/min Wire electrode: G3Si1, 1.2 mm Welding position:...

  • Page 52: Alignment Of Welding Torch Relative To The Workpiece

    'HD' configuration used 'HD' configuration wearing parts, characteristics from 'Speed' configuration used - the characteristics from the Speed configuration were used to prevent an unde- sired "run-off" of the weld pool Alignment of Welding torch (1) at a 45° angle to the welding torch rel- workpiece (2) ative to the work-...

  • Page 53: Standard Welding Parameter Values For Lap Joints

    Standard welding parameter values for lap joints Standard welding NOTE! The following specifications are standard values determined under labo- parameter values ratory conditions. for lap joints Filler metal and welding position: Shielding gas: M21 Ar+18% CO , 2 x 12 l/min Wire electrode: G3Si1, 1.2 mm Welding position:...
  • Page 54 NOTE! If notches appear in the weld seam on the top sheet, adopting the welding torch alignment shown below can prevent these notches from occurring.

  • Page 55: Prerequisities For Welding

    Prerequisities for Prerequisities for CMT Twin welding: welding wearing parts fitted to the torch neck all system components fitted and installed properly compatibility of power sources and remote control systems confirmed...
  • Page 56 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...

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